Being the knowledgable and diverse group of ffellows you are, I thought I would come here to ask abouut this.

So, a couple weeks ago, my friends and I decided that we are going to be the Power Rangers for halloween this coming year. To my surprise, they are willing to take this as far as I am, and that means getting costumes that don't blow and staging a fight with a bunch of people in puddy morph suits.

Our initial thought was to get the power rangers morph suits from morphsuits.com, but upon further examination, they kind of suck. So then I found the suits at zentai-zentai.com and they were alright, but the head parts suck. So we convened today, I shared this with them, and we started talking about getting real helmets. Sadly, prop replicas are like a hundred dollars or more, and there don't seem to be any terribly cheap alternatives. Now, though, I want an actual helmet, and I know I can't just modify an existing helmet because that would suck.

For the helmets, I'll be using pepakura files + Fiberglass cloth and resin, then bondo, or some other filler, to cover them, sand them, and smooth everything out. I'll probably have to get a heat gun and plexi glass for the eye parts.

For the morphers, I'm just going to aquire one of the 50 dollar ones, cast every part in silicon rubber, and assemble a bunch of boot legs.